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William D. Corbett KTA-Tator, Inc.

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1 William D. Corbett KTA-Tator, Inc.
Inspection Planning Keys to Successful In-process QA/QC Inspection During Coating Operations This one-hour webinar is on inspection planning. I delivered a similar webinar about 4 years ago, but challenged myself to think beyond the preparation of an inspection plan and think about what elements are involved in preparing for a project where quality assurance and quality control inspection of surface preparation and coating work will be performed. William D. Corbett KTA-Tator, Inc.

2 Webinar Content Planning to perform inspection of coating operations
Comprehending project documents Gathering referenced standards Verifying correct type and functionality of inspection instruments Verifying safety training and site-compatible PPE Understanding documentation procedures & formats Developing an Inspection Plan Purpose and benefits Common formats Preparation I’ll discuss a variety topics relating to inspection planning, including: Reading and comprehending the contract documents; Gathering referenced standards; Verifying correct type and functionality of inspection instruments; Verifying safety training and site-compatible PPE; and Understanding documentation procedures & formats that may be invoked I’ll also describe the process of developing a written inspection plan, including the benefits and common formats

3 Learning Outcomes Completion of this webinar will enable the participant to: Describe the value and importance of thorough planning to perform inspection of coating operations Describe the purpose, benefits and common formats of a written Inspection Plan Prepare an inspection plan There are three learning outcomes for this webinar. Completing this webinar will enable you to: Describe the value and importance of thorough planning to perform inspection of coating operations Describe the purpose, benefits and common formats of a written Inspection Plan; and with some practice Prepare an inspection plan

4 INSPECT PREPARE A recommended approach to successful coatings inspection is to first plan, then prepare, then inspect. Each of these three stages has multiple steps. Good inspection starts with planning. If you don’t know where you are headed any road will take you there. Arguably this is one of the more challenging elements of quality control and quality assurance inspection of coating work. But putting together a plan of what to inspect, how to inspect, the frequency of inspections, and what the project specification requires is the foundation for a successful inspection project. Once a plan is established, a QA or QC inspector can then begin the second stage which is preparation. An inventory of what is going to be needed for all aspects of an inspection needs to be taken. This includes inspection equipment, PPE, training, medical surveillance and a host of other items that will be discussed in this webinar. The third and final stage is the inspection of quality itself. Without the first 2 steps the top of the pyramid may not be achievable or may lead to problems when production begins PLAN

5 Comprehend Project Documents
Obtain a copy of the coating specification (the key document!) Obtain copies of manufacturer’s product data sheets Read & comprehend all Watch for discrepancies Prepare a list of questions The first step in the planning stage is to read and comprehend the project documents. This includes the coating specification, and technical special provisions specific to the project, clarifications from the pre-job conference, and the coating manufacturer’s product data sheets. Reading and comprehending are different. Make sure you do both. Use a highlighter. Keep a look out for discrepancies between the various documents and prepare a list of questions and clarifications that you need in order to proceed. Don’t be embarrassed to ask clarifying questions. No one knows everything. You may find an error that was overlooked and could cause problems down the road. From these documents, we’ll prepare an inspection plan. This will be described later in this webinar.

6 Gather Referenced Standards
Review “referenced standards” section of the specification Obtain copies of industry standards (watch version) E.g., ASTM, NACE, SSPC, etc. Read and comprehend Standards change over time The second step in the planning stage is to gather, read and comprehend the industry standards that are referenced in the specification. Well-prepared specifications will include a reference section which lists each referenced document contained in the specification itself. Standards from ASTM, SSPC and NACE are common; others may be industry-specific, like AWWA for water tanks and API for petroleum tanks. You’ll need to select those from the list that are quality-related and acquire them, recognizing that they are often protected by copyright and you may need to be a member of the organization to get them, or you may need to purchase them. Some specifications will indicate a specific year of a standard, for example ASTM D or it may simply list the standard without a reference to a date, which often means that the latest version of the standard applies. This is critical. Different versions of industry standards may contain different procedures. For example, ASTM D requires 3 surface profile measurements per area when using the replica tape method, while the 2014 version only requires two per area.

7 Verify Correct Type and Functionality of Inspection Instruments
Review specification for required instruments & visual guides Compatibility of probes Operation Currency of calibration Verification of accuracy Battery status Expendables Now we’ll move from the planning stage to the preparation stage. While you are reviewing the specification create a list of inspection instruments and visual guides you will need to perform your inspections. Consider whether you need remote probes for better access to surfaces. If you are inspecting a coating applied to aluminum, a magnetic induction dry film thickness gage will be of little use to you. If the specification invokes method B of ASTM D4417, which is a depth micrometer for measurement of surface profile and you mobilize to the site with replica tape, you cannot inspect the depth of the profile, even though replica tape is what you are used to using. Other items to consider include whether your gages are operating properly and whether calibration is current. It’s amazing how quickly a year goes by. Check the calibration stickers and the Certificates of Calibration to verify they are current and will remain current throughout the project. Verify the accuracy of the gages when applicable. Even though their calibration is current, they may not be functioning properly. Also verify that you have fresh batteries in the inspection gages that use battery power. New batteries are inexpensive compared to downtime. Make sure you have spare batteries on hand as well. Finally, think about those expendables or one-time use items. Replica tape, surface salt testing supplies, abrasive testing supplies and other expendables. Running out of those items on the job can result in project delays, even if you can get them a day later.

8 Verify Safety Training and Site-Compatible PPE
Currency of general safety training Site-specific safety training Medical surveillance Site-specific PPE PPE compatible with site conditions The next step in the preparation stage is safety-related. Before you mobilize to a plant or to a construction site, verify that your safety training is current and that you are able to show proof of that training upon request. This is easy to overlook. For example you may have been working in a shop, then you are mobilized to a tank lining project where confined space training is required. Also many plants require site-specific training that their safety officers provide. Recognize that this site specific training may take a few hours or even a day or so to complete. Make sure your medical surveillance records are up-to-date. Blood tests, urinalysis and perhaps even chest x-rays may be required before you mobilize to the site. Consider what personal protective equipment or PPE you will need. These requirements are dictated by the hazards present on the project site. A hard hat and eye protection are almost always required. It is doubtful that you will wear a life vest when performing coating inspection in a blast & paint shop… in fact everyone will know who you are and where you are if you do. But if you show-up on a dam gate rehab project without one you wont get very far. Same with a reflective traffic vest on a bridge rehab project. Consider whether fire retardant coveralls are required; think about the type of cartridges you need for your respirator, for example organic vapor or high efficiency particulate air or HEPA filters and how many replacements do you need. When fall prevention is required, consider whether your protection is compatible with site conditions. For example will you be tying off to vertical lifelines or horizontal life lines? If you will be doing you inspections from a man lift consider what you may need to tie off to inside the basket. And verify that your harness and lanyard system current and in good condition.

9 Understand Documentation Procedures & Formats
Many types of forms Electronic or handwritten? Some forms are designed to auto-populate directly from the inspection gage Your forms? Someone else’s forms? Get clarification on entries Who needs to sign them (besides you)? Distribution? The next step in the preparation process is to consider what type of documentation is required. While electronic documentation is certainly becoming more mainstream, some owners may still require handwritten reports. Many electronic gages will download stored data directly into report forms, minimizing the need to manually enter or transfer data and transmittal errors. Consider whether you will use the standard documentation forms your company provides or whether special documentation forms are to be used. You may not be familiar with these so obtain blank copies before the project begins and get clarification if you don’t understand how to populate a specific field on the form. While inspection forms should be intuitive, many are not. Finally make sure you know who all needs to review and sign the documentation forms and the distribution process. That is, who all gets copies of your completed reports?

10 Prepare an Inspection Plan
What is an Inspection Plan? A road map for QA and QC inspection personnel Lists what to inspect, how to inspect and what is acceptable according to the project specification Prevents missed inspection check points/hold points Enables QA and QC personnel to focus on inspection requirements in a project specification The last step in the planning stage is the preparation of an inspection plan. An inspection plan is a road map for quality assurance and quality control inspection personnel. It is essentially a multi-column form listing the inspection check points, the method of inspection and the acceptance criteria, all drawn from the governing specification. The creation of an inspection plan forces the inspectors to thoroughly read and comprehend the specification and helps to avoid missed inspection check points, and allows the inspection personnel to focus on the quality requirements of the project.

11 Purpose of an Inspection Plan
A systematic inspection and testing plan that covers all phases of work in sequence A tool enabling QA/QC inspectors to navigate through and extract inspection check points from the specification May be a required contract submittal So for those of us that may not enjoy paperwork, this topic begs the question: why create an inspection plan, when all of the inspection requirements and acceptance criteria are already described in the specification? The reason is that a thorough, well-organized inspection plan provides an inspector with a systematic tool that covers each phase of work in the general sequence in which it will likely be performed. In general, an inspection plan is a written document that lists what must be inspected, how it is to be inspected and the acceptance criteria from the specification. Coating specifications are often complex documents and frequently contain both technical and legal or contractual requirements. The process of developing an inspection plan provides the inspector with an opportunity to carefully navigate through the contract, extract the inspection check points and transfer them to a separate chart that can be referenced throughout the project to clearly understand and communicate the quality requirements of the specification. Some specifications require the contractor to develop a Work Plan and a Process Control Plan or PCP. The inspection plan is a component to the process control plan. These items are considered “submittals” and oftentimes must be submitted and approved before production operations are allowed to begin.

12 Benefits of a Coatings Inspection Plan
Specifications typically contain the quality requirements for a coatings project Good inspection doesn’t happen by accident; it requires planning Inspection plans make specification enforcement more streamlined and complete Provides a key communication tool between QA and QC inspection personnel Coating specifications typically contain multiple parts, sections and items. The quality requirements for a coatings project are oftentimes contained in the Execution section of the specification, but may be scattered in other parts or sections as well. Proper quality assurance and quality control inspection doesn’t happen by accident. One of the many keys to quality inspection is careful planning, so that each check point is properly inspected using the techniques, instruments, standards, guides and test methods established by the industry to verify the adequacy of the work before proceeding to the next step. The development of a well-organized, thorough inspection plan prior to production activities commencing can help quality assurance and quality control inspection personnel verify that each of the specification requirements are being inspected. It is a key communication tool between contractor and inspector personnel that clarifies what will be inspected, how and when the inspection will take place and the quality requirements of the specification.

13 Required Items for Developing an Inspection Plan
Documents Project specification Referenced standards (SSPC, NACE, ASTM, etc.) Product data sheets SDS Inspection Equipment and Guides The project specification and referenced standards will identify the appropriate test methods and equipment required There are four documents that will serve as references during the development of an inspection plan. They include a copy of the specification and any notes from the pre-construction conference that may become part of the specification; and all of the referenced standards from the specification, including those from SSPC, NACE International, ASTM International and others. Current product data sheets, application instructions and safety data sheets or SDS from the coating manufacturer for each product are also acquired. Technical data sheets and SDS should also be obtained from the abrasive supplier or any supplier of surface preparation-related products or chemicals. While SDS have little to do with quality, they are required to be on-site, and read and understood by all personnel who will potentially come into contact with the product during its use. The project specification should be carefully read to identify each requirement and the owners expectation. It may be beneficial to highlight the inspection requirements as they are read. Recognize that the requirements may not be stated in the specification in the order that they will occur during execution of the work; for example, a specification may establish the surface preparation requirements, then requirements for containment of the structure, followed by requirements for a certified coatings inspector. The specification should establish each inspection test method to be used, the equipment necessary to perform each test, and the frequency at which each test should be performed. Referenced standards detail how to perform a specific test, but typically do not identify the frequency that a test should be performed. All inspection equipment necessary to complete a successful inspection should be verified for accuracy prior to beginning work and maintained in good working order throughout the project. The inspector should prepare and maintain a log of the inspection equipment used on each project.

14 Inspection Plan Format
Variable, depending on contract documents and inspector preference Simple (three columns) Inspection Check Point Method of Inspection Acceptance Criteria Complex Simple format, plus three additional columns Testing Frequency Standard Test Method Reference Specification Reference (Part/Item No.) There is no standard format for inspection plans. The format may be dictated by the specification, or may be customized based on inspector preference. I’ll be illustrating two formats: a simple 3-column format and a more complex 6-column format. The simple format contains 3 column headers including a column to list the inspection check points from the specification, a column to list the methods and instrumentation that will be used to perform the inspections and a third column to list the acceptance criteria corresponding to each inspection check point, which is provided in the specification. The more complex format contains these same 3 columns, but includes 3 additional columns where the testing frequency, the standard test method reference, and a reference to the specification part, section and item number are listed for each inspection checkpoint. The latter column is particularly useful when there is a need to go back into the specification for confirmation, clarifications, etc. It directs the user to the section where the inspection check point and the acceptance criteria are indicated.

15 Inspection Plan Format (simple)
Inspection Item Technique/Instrument Acceptance Criteria This slide illustrates the simple, 3-column format. The first column lists examples of inspection actions, the second column indicates how the inspections will be conducted and the last column lists the acceptance criteria which has been extracted directly from the specification. However, this simple format does not indicate how often to perform a blotter test, or does not list the test method used to measure the conductivity of the abrasive.

16 Inspection Plan Format (complex)
Inspection Item Technique/ Instrument Frequency of Tests Standard Test Method Reference Spec. Reference Acceptance Criteria This slide illustrates a more complex 6-column format. Note that columns 1, 2 and 6 are identical to the earlier 3-column format, however the addition of three columns, which are highlighted in yellow provides additional information to the inspector, including the frequency in which the inspections are required to take place – column 3, the standard test method that describes how to perform the test – column 4, and the section of the specification where the details can be located, if required – column 5. This format is preferred since it provides inspection personnel with a more complete tool.

17 Common Inspection Hold Points
Pre-surface preparation Post-surface preparation Surface conditions for coatings application Coating application Post-coating application Final inspection Hold points are described as those points during surface preparation and coating application where production stops and the work performed is inspected for conformance. If an inspection does not occur at a hold point, it is possible that non-conforming work may be coated over, or the structure may be put into service with a compromised coating system, which may lead to failure. When inspections occur at hold points and non-conforming work is corrected before proceeding to the next step, the risk of coating failure is reduced. Common hold points include pre- and post-surface preparation; evaluation of surface conditions prior to coating; coating application; post-coating application; curing; and final inspection. Note that each of these hold points has multiple check points, each of which should be listed on the inspection plan. We’ll look at these next.

18 Hold Point 1 Pre-Project & Pre-Surface Preparation
Examples of inspection check points Contractor submittals Surface preparation media Coatings materials Containment and ventilation Waste management Surface contamination Oil, grease and debris Soluble salts This is a list of a few of the common items that are typically inspected or verified before the contractor begins surface preparation work. Many specifications require contractors to prepare a number of submittals for the owner prior to beginning work. These submittals often include detailed progress work schedules, worker safety plans, waste management plans, and other engineering drawings or plans. Prior to beginning surface preparation work, the inspector verifies that the contractor has acquired the appropriate surface preparation media and coatings materials based on the requirements of the specification. Containment materials, installation of the containment and ventilation system, required air and site monitoring, and waste management plans are verified for conformance to the specification requirements and submitted prior to beginning surface preparation work. In addition, the surface of the structure is examined to identify any areas of surface contamination; such as heavy deposits of oil, grease, debris, or soluble salts, as these areas often require pre-cleaning and inspection before mechanical surface preparation begins.

19 Hold Point 2 Post-Surface Preparation
Examples of inspection check points Ambient conditions Surface preparation media Removal of surface contamination Surface cleanliness Surface profile Surface imperfections Waste management Although hold point 2 is identified as post-surface preparation, some of the inspection check points such as ambient conditions, surface preparation media, and removal of surface contamination is verified or inspected prior to and throughout the surface preparation phase of work. Other check points include examining the cleanliness of the surface after mechanical methods of preparation are performed, as well as the surface profile yield if invoked by the contract documents. Surface imperfections observed during surface preparation, or caused by surface preparation operations are documented and addressed prior to coating system installation. Finally, the inspector may also be required to verify that the waste generated during surface preparation activities is properly stored and secured until it can be removed from the project site.

20 Hold Point 3 Surface Conditions for Coatings Application
Examples of inspection check points Surface cleanliness Ambient conditions Recoat windows Performed for each coating applied Conditions for coating installation include inspection of prepared surfaces for dust or other debris that may inhibit surface wetting of the coating or adhesion; verification that the air and surface temperatures, as well as the relative humidity are within the allowable ranges, and that the surface temperature is warmer than the dew point temperature to preclude moisture formation on prepared surfaces. Once the coating is applied, the inspector verifies that the coating has cured for the minimum time, but has been overcoated before exceeding the maximum recoat time. These inspection check points are performed for each coating layer to be applied.

21 Hold Point 4 Coating Application
Examples of inspection check points Coatings materials Mixing, thinning and straining Ambient conditions Wet film thickness Coatings application defects Performed for each coating applied The coating application check points include verification that the coating materials on-site are the correct products that have a current shelf life, and that they are mixed, thinned and strained according to the manufacturers instructions. Again, the prevailing conditions of temperature and humidity are measured and recorded, and the applied wet film thickness may be measured and recorded, especially when dry film thickness measurements are not possible. The applied coating should also be inspected for visible defects that occurred during application, so that they can be repaired prior to application of the next coat. These inspection check points are performed for each coating layer to be applied.

22 Hold Point 5 Post-Coating Application
Examples of inspection check points Dry film thickness (each coat) Recoat window/free of contamination (each coat) Coating application defects (each coat) Pinhole / holiday detection (buried/ immersion service) Measuring the thickness of the coating after each layer is applied is a critical post-coating application inspection check point. A host of manual and electronic gages are available for quantifying coating thickness. Gage use is described in ASTM D7091; the frequency of measurement and the acceptability of the measurements are described in SSPC-PA 2. Observing the minimum and maximum recoat windows and verifying cleanliness between coats can be significant factors in minimizing premature coatings failure, and are typically performed for each coating layer to be applied. Identifying and correcting film defects prior to application of the next coating layer is also critical; and pinhole or holiday detection is often invoked for tank interior surfaces, vessels, railcar linings and pipeline.

23 Hold Point 6 Final Inspection
Examples of inspection check points Repair and touch-up Waste removal Site restoration Verification of corrective action implementation Final inspection includes examination of repaired areas, as well as removal of waste by a licensed transporter, restoring the site to its original condition, and verification that corrective actions have been implemented by the contractor.

24 Let’s Develop an Inspection Plan
Example based on maintenance painting of a bridge structure First, populate from the specification: Column 1: Inspection check point column Column 3: Frequency of test column Column 5: Specification reference column Column 6: Acceptance criteria column Second, populate inspection method (Column 2) and standard test method (Column 4) Now that we have described the purpose and benefits of an inspection plan, described two basic formats, and listed common inspection check points found in coating specifications, it is time to develop an inspection plan based on a simulated project entailing maintenance painting of a bridge structure. During this demonstration, we will be using the 6-column complex format. While it will not be possible to view the specification on the slides, the inspection plan will be populated based on a simulated specification. First, we will populate columns 1, 3, 5 and 6 directly from the specification, then back fill columns 2 and 4 based on the inspection method and industry standard referenced by the specification. At first, we will illustrate the development of the inspection plan row-by-row, as indicated by the yellow highlighted rows. After a few sample rows, we will illustrate several populated rows all at once.

25 Inspection Plan for Maintenance Painting of a Bridge Structure
Inspection Item Technique/ Instrument Frequency of Tests Standard Test Method Reference Spec. Reference Acceptance Criteria Verify grease/ oil removal 100% of surfaces, prior to surface prep. No visible oil or grease contamination The first inspection check point addresses verification of grease and oil removal. Inspection of all surfaces is required and no visible oil or grease contamination is permitted. This detail is located in Section 45, Part 2.03 of the simulated specification.

26 Inspection Plan for Maintenance Painting of a Bridge Structure
Inspection Item Technique/ Instrument Frequency of Tests Standard Test Method Reference Spec. Reference Acceptance Criteria Verify grease/ oil removal 100% of surfaces, prior to surface prep. No visible oil or grease contamination Verify surface chloride removal Three tests per 1000 sq. ft. < 7 µg/cm2 The second inspection check point addresses verification of surface chloride removal. Three tests in each of 1000 square feet is required and surface concentrations must be maintained below 7 micrograms per square centimeter. This detail is also located in Section 45, Part 2.03 of the specification.

27 Inspection Plan for Maintenance Painting of a Bridge Structure
Inspection Item Technique/ Instrument Frequency of Tests Standard Test Method Reference Spec. Reference Acceptance Criteria Verify grease/ oil removal 100% of surfaces, prior to surface prep. No visible oil or grease contamination Verify surface chloride removal Three tests per 1000 sq. ft. < 7 µg/cm2 Verify correct abrasive type & cleanliness Each lot Expendable; angular; no oil; <1000 µMho/cm The third inspection check point addresses verification that the correct abrasive has been brought on to the site and that it is clean. Each lot of abrasive must be tested, and the abrasive must be an expendable type that is angular in shape. The abrasive cannot contain any visible oil contamination and must have a conductivity of less than 1000 micro-mho per centimeter This detail is located in Section 45, Part 2.04 of the specification.

28 Inspection Plan for Maintenance Painting of a Bridge Structure
Inspection Item Technique/ Instrument Frequency of Tests Standard Test Method Reference Spec. Reference Acceptance Criteria Verify grease/ oil removal 100% of surfaces, prior to surface prep. No visible oil or grease contamination Verify surface chloride removal Three tests per 1000 sq. ft. < 7 µg/cm2 Verify correct abrasive type Each lot Expendable; Angular Verify compressed air cleanliness Once per shift No visible oil or water on collector The fourth inspection check point addresses verification that the compressed air used for abrasive blast cleaning and blow down is clean and dry. The air must be tested a minimum of once per shift, and there can be no visible oil or water on the collector. This detail is located in Section 45, Part 2.04 of the specification.

29 Inspection Plan for Maintenance Painting of a Bridge Structure
Inspection Item Technique/ Instrument Frequency of Tests Standard Test Method Reference Spec. Reference Acceptance Criteria Verify grease/ oil removal 100% of surfaces, prior to surface prep. No visible oil or grease contamination Verify surface chloride removal Three tests per 1000 sq. ft. < 7 µg/cm2 Verify correct abrasive type & cleanliness Each lot Expendable; angular; no oil; <1000 µS/cm Verify compressed air cleanliness Once per shift No visible oil or water on collector Verify post-blast surface cleanliness 100% of surfaces, prior to primer appl. SSPC-SP 10 The fifth inspection check point addresses surface cleanliness. Inspection of all surfaces is required and must meet the minimum requirements of SSPC-SP 10 Near-white Blast. This detail is also located in Section 45, Part 2.04 of the specification.

30 Inspection Plan for Maintenance Painting of a Bridge Structure
Inspection Item Technique/ Instrument Frequency of Tests Standard Test Method Reference Spec. Reference Acceptance Criteria Verify surface profile depth Three tests per area cleaned, per shift 1.5-3 mils Verify surface prep.-to-primer interval After final surface prep., per area Within same day as blast cleaning Verify dust removal Prior to primer appl. No visible dust Verify correct coating mat’ls. Prior to surface prep. OZ/EP/PU from 1 manufacturer Coating thickness After each coat Primer: 3-5 mils Interm: 5-7 mils Finish: 2-3 mils Verify finish coat color Prior to finish coat appl. Fed. Std. 151B No The next six inspection check points include verification of surface profile depth, surface preparation-to-primer time interval, dust removal, correct coating materials, coating thickness and finish coat color. The testing frequency and acceptance criteria from the specification is shown for each, as is the specification reference section. The profile depth is measured in 3 locations for each area prepared during the shift and must be mils deep. Surfaces must be primed-in the same day they are prepared and there can be no visible dust on the surface prior to primer application. This detail is located in Section 45, Part 2.04 of the specification. The coatings consist of an organic zinc-rich primer, an epoxy midcoat and an acrylic polyurethane finish coat. The dry film thickness is 3-5 mils for the primer, 5-7 mils for the midcoat and 2-3 mils for the finish coat, which must be Federal Color No This detail is located in Section 45, Part 2.05 of the specification.

31 Inspection Plan for Maintenance Painting of a Bridge Structure
Inspection Item Technique/ Instrument Frequency of Tests Standard Test Method Reference Spec. Reference Acceptance Criteria Measure ambient conditions & surface temp. Prior to coating mixing and 4 hr. intervals Air & Surf. Temp: 40-100°F RH: <85% ST +5°F of DP Verify proper mixing of coatings During mixing Mechanical mixing blade Verify straining of primer Prior to trsfr. to spray pot Strained Verify proper thinning Prior to addition Type & amount per manuf. PDS Verify lighting Prior to production Surf. prep & ctg appl: Min 20 fc Prior to inspection Minimum 50 fc The next six inspection check points include measurement of ambient conditions and surface temperature, verification of proper mixing, thinning and straining of the coating materials, and verification of minimum lighting for production and inspection operations. The testing frequency and acceptance criteria from the specification is shown for each, as is the specification reference section. Ambient conditions are measured prior to coating mixing and at 4 hour intervals thereafter, unless conditions appear to be changing. Air and surface temperatures must be maintained between 40 and 100 degrees F and the relative humidity cannot exceed 85%. The surface temperature must be a minimum of 5 degrees F higher than the dew point. Mixing must be performed using a mechanical mixing blade, and the primer must be strained before it is transferred to the spray pot. The thinner type and amount must conform to the manufacturer’s PDS, and lighting inside the containment area must provide a minimum of 20 foot candles for surface preparation and coating work, and a minimum of 50 foot-candles for inspection work. This detail is located in Section 45, Parts 2.06 and 2.07 of the specification.

32 Inspection Plan for Maintenance Painting of a Bridge Structure
Inspection Item Technique/ Instrument Frequency of Tests Standard Test Method Reference Spec. Reference Acceptance Criteria Verify spray pot agitation During primer application Constant agitation during appl. Stirrer w/i 2” from bottom Verify primer appl. by spray Prior to primer appl. Spray Verify intercoat cleanliness Prior to each successive coat No moisture, dust, grease, etc. Verify recoat intervals Minimum and maximum per PDS Verify workmanship After appl. of each coat No runs, drips, sags or misses The next five inspection check points include verification of pot agitation, application method for the primer, intercoat cleanliness, recoat intervals and quality of workmanship. The testing frequency and acceptance criteria from the specification is shown for each, as is the specification reference section. The primer must be constantly agitated during application, and there is a requirement for the depth of the stirrer. The primer has to be spray-applied, and no moisture, dust or grease may be present on coated surfaces. The recoat intervals cannot be any less than the manufacturer’s stated minimum, nor any greater than the manufacturer’s maximum time period, and the applied coating cannot contain any runs, drips, sags or misses. This detail is located in Section 45, Parts 2.07 and 2.08 of the specification.

33 Inspection Plan for Maintenance Painting of a Bridge Structure
Inspection Item Technique/ Instrument Frequency of Tests Standard Test Method Reference Spec. Reference Acceptance Criteria Verify enclosure integrity Daily No damage to work, property or persons Verify proper stenciling Prior to demobilization 45-3 Proper location, size, content and color Verify time of operations Daylight hours only The last three inspection check points include verification that the integrity of the containment remains intact throughout the project and that no damage to work, property or site personnel occurs. This information is located in section of the specification. Stenciling of the structure is required prior to demobilization, as described in section 45-3; and surface preparation and coating work can only occur during daylight hours, as noted in sections and 2.05 of the specification.

34 Inspection Plan for Maintenance Painting of a Bridge Structure
Complete the inspection plan by populating the remaining two columns Inspection instrument/technique Standard test method reference Now that we have populated the first 4 columns of the inspection plan, we can easily go back and populate the inspection method column and the standard test method column for each of the inspection check points previously listed.

35 Inspection Plan for Maintenance Painting of a Bridge Structure
Inspection Item Technique/ Instrument Frequency of Tests Standard Test Method Reference Spec. Reference Acceptance Criteria Verify grease/ oil removal Visual and/or water break 100% of surfaces, prior to surface prep. SSPC-SP 1 No visible oil or grease contamination Verify surface chloride removal Latex patch/sleeve Cl- strip/tube Three tests per 1000 sq. ft. SSPC Guide 15 < 7 µg/cm2 Verify correct abrasive type & cleanliness Visual; Vial test (oil); Conductivity meter Each lot SSPC AB 1; Oil: ASTM D 7237 Conductivity: ASTM D 4940 Expendable; angular; no oil; <1000 µS/cm Verify compressed air cleanliness Blotter test Once per shift ASTM D 4285 No visible oil or water on collector Verify post-blast surface cleanliness SSPC VIS 1 100% of surfaces, prior to primer appl. SSPC-SP 10 Near-white Blast The two yellow highlighted columns list the technique or instrument used to perform the inspection and the standard test method reference, provided one exists. Note that in many cases the technique is visual and no instrumentation is required. To verify grease and oil removal, a visual inspection will be performed, and a water break test may be used on horizontal surfaces. The inspection will be performed as described in SSPC-SP 1 Solvent Cleaning. Surface extraction for chloride contamination will be performed using either the latex patch or latex sleeve methods and detection will be performed using either the chloride indicator strip or tube. Extraction and analysis will be performed according to SSPC Guide 15. The type and angularity of the abrasive will be inspected visually, and a vial test will be performed to verify abrasive cleanliness. A conductivity meter will be used to verify the abrasive does not contain excessive ionic contamination. The cleanliness of the abrasive is evaluated according to SSPC AB 1 for Mineral and Slag abrasives, since abrasive cleanliness is a referenced requirement of SSPC-SP 10, Near-white blast cleaning. The absence of oil contamination will be verified according to ASTM D 7237, and the conductivity of the abrasive will be measured according to the procedure described in ASTM D 4940. A blotter test will be performed according to ASTM D to verify compressed air cleanliness; and SSPC VIS 1 will be used to verify that surfaces have been abrasive blast cleaned to a near-white condition according to SSPC-SP 10.

36 Inspection Plan for Maintenance Painting of a Bridge Structure
Inspection Item Technique/ Instrument Frequency of Tests Standard Test Method Reference Spec. Reference Acceptance Criteria Verify surface profile depth Depth micrometer or replica tape Three tests per area cleaned, per shift ASTM D 4417; SSPC-PA 17 1.5-3 mils Verify surface prep.-to-primer interval Visual After final surface prep., per area NA Within same day as blast cleaning Verify dust removal Visual/tactile Prior to primer appl. No visible dust Verify correct coating mat’ls. Prior to surface prep. OZ/EP/PU from 1 manufacturer Coating Thickness Calib. dry film thickness gage After each coat ASTM D7091; SSPC-PA 2 Primer: 3-5 mils Interm: 5-7 mils Finish: 2-3 mils Verify finish coat color Visual (check label) Prior to finish coat appl. Fed. Std. 151B No Continuing with the two highlighted columns… The surface profile depth is measured according to ASTM D 4417 and at the frequency prescribed by SSPC-PA 17. The surface preparation-to-primer interval, dust removal, verification of correct coating materials and finish coat color are each inspected for visually. Coating thickness is measured using a calibrated dry film thickness gage according to the requirements of ASTM D7091 and SSPC PA 2.

37 Inspection Plan for Maintenance Painting of a Bridge Structure
Inspection Item Technique/ Instrument Frequency of Tests Standard Test Method Reference Spec. Reference Acceptance Criteria Measure ambient conditions & surface temp. Sling psychrometer; psychrometric charts; surf. thermometer Prior to coating mixing and 4 hr. intervals ASTM E 337 Air & Surf. Temp: 40-100°F RH: <85% ST +5°F of DP Verify proper mixing of coatings Visual During mixing NA Mechanical mixing blade Verify straining of primer Prior to trsfr. to spray pot Strained Verify proper thinning Prior to addition Type & amount per manuf. PDS Verify lighting Light Meter Prior to production SSPC Guide 12 Surf. prep & ctg. appl.: Min 20 fc Prior to inspection Minimum 50 fc Again continuing with the two highlighted columns… Ambient conditions and surface temperature are measured using a sling psychrometer, psychrometric charts and a surface temperature thermometer according to ASTM E337; and mixing, thinning and straining are inspected visually. The adequacy of lighting is assessed using a light meter and the minimum and recommended illumination requirements for surface preparation and coating application work, as well as inspection activities are set forth in SSPC’s Guide 12.

38 Inspection Plan for Maintenance Painting of a Bridge Structure
Inspection Item Technique/ Instrument Frequency of Tests Standard Test Method Reference Spec. Reference Acceptance Criteria Verify spray pot agitation Visual During primer application NA Constant agitation during appl. Stirrer w/i 2” of bottom Verify primer appl. by spray Prior to primer appl. Spray Verify intercoat cleanliness Visual/tactile Prior to each successive coat No moisture, dust, grease, etc. Verify recoat intervals Minimum and maximum per PDS Verify workmanship After appl. of each coat No runs, drips, sags or misses Continuing with the two highlighted columns… The spray pot agitation and spray application of the primer, recoat times and the quality of workmanship will all be verified visually; (next slide)

39 Inspection Plan for Maintenance Painting of a Bridge Structure
Inspection Item Technique/ Instrument Frequency of Tests Standard Test Method Reference Spec. Reference Acceptance Criteria Verify enclosure integrity Visual Daily NA No damage to work, property or persons Verify proper stenciling Prior to demobilization 45-3 Proper location, size, content and color Verify time of operations Daylight hours only … as will the integrity of the enclosure, stenciling, and the time of surface preparation and coating application operations.

40 Summary During this webinar, we have:
Described the importance of thorough planning to perform inspection of coating operations Described the purpose, benefits and common formats of an Inspection Plan Prepared an inspection plan based on a simulated bridge coating project In summary, we have described the importance of planning and preparation prior to inspection, and the purpose and benefits of an inspection plan. We explored two formats for inspection plans, including both simple and complex formats, and listed the more common inspection check points for each of six hold points. We also reviewed how to extract the acceptance criteria from the specification for each of the check points. Finally, we prepared an inspection plan for recoating a bridge based on a simulated specification.

41 Inspection Planning Keys to Successful In-process QA/QC Inspection During Coating Operations
Thanks to Fischer Technologies for sponsoring this webinar. Josiah will now open it up for questions. Questions


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